Tokyo Motor Show 2007 Press Information

Transcription

1 CONTENTS Press Information PRODUCTS - New Technology for Power Control Units - DENSO Diesel Development - Motor-Driven Electric Variable Valve Timing Control System - Air Conditioning System with Matrix IR Sensor - Adaptive Front Lighting System (AFS) - MEMS Technology Exhibited Products List DENSO Global Facts President Biography Photo List DENSO Media Contacts CD-ROM (Photos and Texts)

2 New Technology for Power Control Units Silicon carbide (SiC) is a promising material to use in power devices for hybrid vehicle power control units (PCU). Compared to current power devices made of silicon (Si), SiC power devices are expected to help PCUs produce higher power with a smaller size, since SiC can withstand higher voltage and higher temperatures with less power loss than Si. One of the biggest hurdles in commercializing SiC power devices is the need to create SiC wafers with the high crystallinity required in on-vehicle power devices. DENSO has been working to produce higher crystalline SiC wafers, and succeeded in producing SiC wafers with the smallest level of defect density in the world some hundreds per 1 square centimeter. This year DENSO introduced a new PCU for the Lexus LS 600h and the Lexus LS600hL. The PCU consists of a boost converter that raises the main battery voltage (288V) to the maximum system voltage (650V), and two inverters that convert direct current (DC) into alternate current (AC) to drive the main traction motors. For the PCU, DENSO developed a unique cooling structure that significantly improves cooling performance for the power devices. As a result, the newly developed PCU can produce output power that is approximately 60 percent higher per unit volume, compared to the company s conventional technology, thus improving hybrid system performance. When the PCU is designed to produce the same output as conventional technology, it can be reduced approximately 30 percent in size and approximately 20 percent in volume. DENSO will continue to develop innovative technologies using its wide range of technologies and make hybrid products more compact and inexpensive while improving their performance.

3 DENSO Diesel Development Diesel-powered vehicles offer excellent fuel economy and power, and their popularity is especially high in Europe. The percentage of diesel-powered car sales in Western-Europe has nearly doubled to more than 50 percent over the last ten years. DENSO continues to develop diesel engine management systems and components for injection control and after-treatment. This supports vehicle manufacturers to expand the market for clean diesel vehicles. With regards to injection control, late 1995 DENSO launched the world s first innovative diesel common rail system saw the introduction of 180 MPa (1800 bar) systems with five-time multiple injections, achieving the highest injection pressure in the world at that time. The state-of-the art system is produced in Japan as well as Hungary and Thailand. The production of the system is also scheduled to start in China in DENSO has now developed a new diesel common rail system featuring 200 MPa (2000 bar) injection pressure and up to nine injections per combustion stroke, again achieving the highest injection pressure in the world. This new diesel common rail system improves performance and drivability while reducing fuel consumption and emissions such as nitrogen oxide (NOx) and particulate matter (PM). It also helps make aftertreatment systems more effective. DENSO plans to introduce its 200 MPa diesel common rail system next year. For after-treatment, DENSO has been producing and supplying its high performance and cost effective diesel particulate filters (DPFs) made of cordierite since Compared to other materials, cordierite DPFs are light-weight and provide lower back pressure of exhaust gas, delivering better engine performance and more efficient purification of PM in emissions. This June, DENSO established a joint venture with Bosch in Wroclaw, Poland, to produce cordierite DPFs. As a result of the Euro 5 emission standard for cars, DPFs are expected to become standard equipment for all new diesel-powered cars in Europe, rapidly expanding the market for particulate filters.

4 Motor-Driven Electric Variable Valve Timing Control System Vehicles today need to achieve outstanding driving performance with improved fuel economy while reducing harmful substances in emissions. To help meet these requirements, DENSO, together with Toyota Motor Corporation, developed the world s first motor-driven electric variable valve timing control system for the Lexus LS460, launched in September Variable valve timing control systems control the opening/closing timing of intake and exhaust valves, optimizing the airflow in and out of each combustion chamber in accordance with driving conditions. DENSO s electric variable valve timing control system includes a cam phasing mechanism connected to the intake camshaft, a brushless motor, and an electric driven unit (EDU) (Figure 1). Based on signals from the engine ECU (electronic control unit), the EDU operates the motor to control the cam phasing mechanism and directly adjust the opening/closing timing of intake valves. Conventionally, this procedure is controlled hydraulically. As a result, this new system can control intake valve timing more precisely and widely, enabling higher engine output and lower fuel consumption. In addition, even under conventionally difficult operating conditions such as low engine temperature or low engine revolution, the new system precisely controls valve timing, reducing hydrocarbon in emissions and improving drivability. DENSO introduced its first hydraulic variable valve timing system in 1997, and has contributed to the evolution of the system in the market. Currently, the majority of gasoline-powered vehicles are equipped with this system. DENSO will continue its efforts to make variable valve timing control systems more efficient, more compact, and less expensive. - more -

5 Brushless Motor Cam Phasing Mechanism EDU Cam Position Sensor Crank Position Sensor Engine ECU Figure 1. Structure of the motor-driven electric variable valve timing control system

6 Air Conditioning System with Matrix IR Sensor DENSO Corporation has developed a new air conditioning system with the world s first matrix IR (infrared) sensor for vehicles. The new matrix IR sensor, installed on the Lexus LS460 launched in September 2006, enables the air conditioning system to provide more comfortably conditioned air for rear seat passengers. The newly developed matrix IR sensor located in the center of the ceiling panel, detects the surface temperature for each rear seat passenger and converts it into electrical signals, which are sent to the air conditioning ECU (electronic control unit). The air conditioning ECU then calculates the appropriate air conditioning settings to adjust air temperature, airflow, and air outlet mode for each passenger. The matrix IR sensor has multiple sensor elements that detect infrared rays radiated within the vehicle cabin and measure the surface temperature for each passenger. This provides air conditioning more suited to the temperature of each passenger, compared to a conventional system where air conditioning is adjusted according to the cabin s temperature. For example, when a rear seat passenger enters the vehicle from a hot environment, the matrix IR sensor can provide cooler air conditioning to the entering passenger, while maintaining the air conditioning environment for the other passengers. DENSO focuses on the development of technologies and products in the areas of environment, safety, comfort and convenience. The matrix IR sensor is an example of a DENSO product developed to provide a more comfortable environment for passengers. DENSO will continue to focus on these four areas to meet the needs of customers and to contribute to an advanced automotive society.

7 Adaptive Front Lighting System (AFS) Adaptive front lighting systems (AFS) redirect low-beam headlamp units individually in a horizontal direction in accordance with steering angle and vehicle speed. As a result, these systems can improve visibility during nighttime cornering, ensuring safer driving. At, DENSO demonstrated its new AFS, currently under development, which further improves visibility in a curve. The new AFS predicts curves in the road ahead using road information from the car navigation system, and redirects headlamps to illuminate the road, before the vehicle enters the curve. This enhances visibility for the driver sooner. DENSO is working to improve the accuracy of position information from the navigation system before commercializing the new technology. The world s first AFS was developed by DENSO together with Toyota Motor Corporation and Koito Manufacturing Co., Ltd., in For this system, DENSO developed an AFS electronic control unit (ECU) and swivel ECU. In January 2006, DENSO launched its new AFS ECU, which is approximately 70 percent smaller in volume compared to the conventional AFS ECU. In addition to its smaller size, the new ECU can provide more detailed light distribution control in accordance with road conditions and vehicle speed, resulting in improved visibility. DENSO is developing and supplying automobile safety systems and components in two distinct areas: active safety for collision warning and avoidance, and passive safety for damage minimization in the event of collision. In the pursuit of a safer automotive society, DENSO continues to improve safety systems.

8 MEMS Technology -Applied to acceleration sensors and future products- MEMS (micro electro mechanical systems) are microstructures manufactured on semiconductor wafers using semiconductor process technologies. In recent years, MEMS technology has been widely applied to various devices used in sensors, ink-jet printer heads, and other products. DENSO has developed a new technology for MEMS that allows a trench that is deeper and narrower than was possible before, and is applying this technology to automotive acceleration sensors and future products such as a micro laser scanner. Semiconductor Acceleration sensor: As automotive safety technologies progress, the demand for smaller and less expensive semiconductor acceleration sensors is increasing. With its advanced MEMS technology, DENSO is supplying the world s smallest automotive semiconductor acceleration sensors for safety systems such as airbag systems, vehicle stability control systems and anti-lock braking systems. The acceleration sensor has a sensor element composed of fixed and movable electrodes that detect acceleration from a change in capacitance, and a control circuit that converts the change in capacitance to an electric signal. DENSO s advanced MEMS technology for sensor elements enables the world s thickest fixed and movable electrodes to be formed on an SOI (silicon-on-insulator) substrate using only a dry etching process. Usually both wet and dry etching processes are needed. This technology simplifies manufacturing processes and improves production yield, resulting in a lower cost acceleration sensor. The world s thickest fixed and movable electrodes - 15 micrometers - provide a wide detection range and high reliability. - more -

9 Future Products: DENSO has continuously improved its semiconductor technologies since the early 1970 s, developing a number of groundbreaking products. Now it is applying the technologies and expertise cultivated in acceleration sensors to create new products. One such product is a micro laser scanner composed of micro prisms and laser diodes. DENSO currently is developing a scanner that is approximately 1/100 th the size smaller than a conventional mechanical laser scanner, by manufacturing aligned micro prisms using MEMS technology. DENSO expects to use the micro laser scanner for automotive systems.

10 Exhibited Products List Products Contributing to the Environment Diesel Engine Management System - Supply pump - Common rail - Piezo injector - Crank position sensor - Manifold absolute pressure sensor - Air flow meter - Electronic throttle body - EGR (Exhaust gas recirculation) valve - Intercooler - Glow plug - Air-fuel ratio sensor - Exhaust gas temperature sensor - Exhaust gas pressure sensor - Exhaust port fuel injector - DPF (Diesel-particulate filter) - ECU (Electronic control unit) - Electronic injector driver unit Gasoline engine management components - High pressure injector - High pressure pump - Fuel pressure sensor - Fuel pump module - Stick coil - Iridium spark plug - Crank position sensor - Electronic throttle body - Air flow meter - Intake variable cam timing - Exhaust variable cam timing - Manifold absolute pressure sensor - Air-fuel ratio sensor - Oxygen sensor - Catalytic substrate - Electronic injector driver unit - more -

11 Products Contributing to the Environment Motor-driven electric variable valve timing control system Hybrid vehicle components - Power control unit - DC-DC converter - Battery monitoring unit - High voltage relay - Battery current sensor - Hybrid vehicle ECU Products Contributing to Safety Sensing system - Millimeter-wave radar sensor - Vision sensor - Driving support system ECU Products Contributing to Comfort Car air conditioner - HVAC unit - Matrix IR (infrared) sensor - External variable displacement compressor - Condenser Key Technology MEMS ( Micro Electro Mechanical Systems ) - Acceleration sensor for airbag system - Microprism

12 FACTS DENSO Global Facts CORPORATE HEADQUARTERS DENSO CORPORATION, Kariya, Aichi, Japan TOP MANAGEMENT Chairman: Akihiko Saito President and CEO: Koichi Fukaya ESTABLISHED December 16, 1949 GLOBAL OPERATIONS (as of March 31, 2007) Subsidiaries/Affiliates (in Japan): 82 Subsidiaries/Affiliates (outside Japan): 138 GLOBAL EMPLOYEES (as of March 31, 2007) 112,262 GLOBAL FINANCIAL RESULTS Consolidated Net Sales: 3,609.7 billion Yen (US$30.6 billion or 23.0 billion Euro) Consolidated Net Income: billion Yen (US$1.7 billion or 1.3 billion Euro) Fiscal Year: Ended March 31, 2007 Note: US$ and Euro amounts have been translated, for convenience only, at a rate of 118 Yen = US$1 and 157 Yen = 1 Euro, the approximate exchange rate prevailing on March 31, Billion is used in the American sense of one thousand million. - more -

13 FACTS REGIONAL HEADQUARTERS The Americas: DENSO International America, Inc., Southfield, Michigan Europe: DENSO EUROPE B.V., Weesp, the Netherlands Asia/Oceania: DENSO International Asia Pte. Ltd., The Aires, Singapore China: DENSO (China) Investment Co., Ltd., Beijing, China COUNTRIES : 32 Japan, United States, Canada, Mexico, Brazil, Argentina, Netherlands, United Kingdom, Germany, Spain, Italy, France, Hungary, Sweden, Poland, Belgium, Portugal, Czech Republic, Turkey, Australia, Singapore, Thailand, Indonesia, Republic of Korea, Malaysia, India, Taiwan, China, Philippines, Saudi Arabia, Vietnam and South Africa, OPERATING SUMMARY BY INDUSTRY SEGMENT <Automotive sub-total: 96.7 percent of global net sales> Thermal Systems: 31.5 percent Powertrain Control Systems: 23.0 percent Information and Safety Systems: 16.2 percent Electric Systems: 9.2 percent Electronic Systems: 8.6 percent Small Motors: 6.9 percent Other Automotive: 1.3 percent <New businesses sub-total: 3.3 percent> Industrial Systems and Consumer Products: 1.8 percent Others: 1.5 percent WEB SITE

14 BIO Koichi Fukaya President and CEO, DENSO Corporation Koichi Fukaya began serving as President and CEO of DENSO Corporation, headquartered in Kariya, Aichi, Japan in June Since then, Fukaya has taken DENSO on a fast track toward creating innovative technology for an advanced automotive society. In addition, his boosting of global operations to better serve DENSO s customers worldwide resulted in a continuous increase of both revenue and profit. Previously, Fukaya served as Senior Managing Director in charge of the Production Promotion Center. There, he was responsible for strategic planning and implementation of production technologies for DENSO Group manufacturing, to achieve high quality in technology, product development and production. In 1995, Fukaya was appointed to the Board of Directors and named President of DENSO Manufacturing Michigan, Inc. in Battle Creek, Mich., USA. While there, he succeeded in expanding sales to General Motors. After four years in Michigan, he took his post in 1998 as Managing Director of the Production Control Department, and in 1999, was made responsible for the Thermal Systems Group. While Managing Director of the Thermal Systems Group, DENSO s largest product group, Fukaya led the development of modules such as the cockpit and front-end modules. He also led the expansion of DENSO s European business by increasing sales and establishing a third air conditioner plant in the Czech Republic. - more -

15 BIO Fukaya also served as General Manager of the Production Engineering Department, the Production Engineering Research & Development Department and the Air conditioning Manufacturing Department. During his tenure at DENSO, Fukaya has researched automatic assembly systems, developed flexible manufacturing systems and established advanced production systems leading to several production and technology awards. Fukaya joined DENSO Corporation (formerly Nippondenso Co. Ltd.) in 1966 after graduating with a degree in Mechanical Engineering from the Tokyo Institute of Technology. His major areas of study included material strength, thermodynamics, aeromechanics and automatic control systems. DENSO, a leading global supplier of advanced automotive technology, systems and components, employs approximately 112,000 people in 32 countries and regions, including Japan. Consolidated global sales for the fiscal year ended March 31, 2007 totaled US$30.6 billion.

16 PHOTOS Koichi Fukaya President and CEO DENSO Corporation 200 MPa (2000 bar) Diesel Common Rail System Matrix Infrared Sensor High-Output Power Control Unit AFS ECU Electric Variable Valve Timing Control System Microscope Image of Acceleration Sensor (Magnification 2000)

17 CONTACTS DENSO Media Contacts CORPORATE HEADQUARTERS DENSO Corporation Miwa Kurokawa Goro Kanemasu NORTH AMERICAN HEADQUARTERS DENSO International America, Inc. Marlene Goldsmith Julie Kerr EUROPEAN HEADQUARTERS DENSO Europe B.V. Sjoerd Dijkstra Shink Omi WEBSITES Worldwide: N. America: